Corrugated sheet



Nov. 27, 1934. G E BLACK 1,982,243

CORRUGATED SHEET Filed NOV. 13, 1930 I N VEN TOR.

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Patented Nov. 27, 1934 mirri-:Nifv 4OFI-ics CORRUGATED SHEET George E. Black, sowiokley, ra., assignor to, n. H.

Robertson Company, Pittsburgh, Pa., a corporation of Pennsylvania Application November 13, 1930, sonal No. 495,454

1 Claim.

The invention further has for its object to pro` duce the improved'corrugated sheetin a novel manner as will be'described.

To these ends, the improved corrugated sheet,4

which will be hereinafter referred to as a corrugated metal sheet, is provided in its body portion 10 with substantially V-beam corrugations of substantial depth and at its opposite sides with substantially V-beam corrugations of lesser depth, the outside walls of one or both ofthe side corrugations of lesser depth being inclined at a sharper angle than correspondingly inclined walls of the intermediate deeper corrugations of said sheet, whereby a more effective weather-tight joint may be made between contiguous V-beam corrugated sheets, as will be described.

The outside walls of the V-beam corrugations of lesser depth may be made of unequal widths for purposes as will be described.

These and other features of this invention will be pointed out in the claim at the end of this specification.

Fig. 1 is a plan view of a portion of a corrugated metal sheet embodying this invention and produced in a novel manner as will be described;

Fig. 2, an end view of the corrugated metal sheet shown in Fig. 1;

Fig. 3, a sectional detail on a larger scale of a preferred .construction of asphalt-protected metal sheet embodying the invention;

Figs. 4 and 5; diagrammatic views to illustrate a preferred method of making the improved corrugated metal sheet;

Figs. 6 and 7, diagrammatic views to illustrate certain reactions in the metal sheet subjected to the steps of the process by which a fiat sheet is converted into the improved sheet illustrated in Figs. 1, 2 and 5, and

Fig. 8, an end elevation 'of two of the improved protected metal sheets -in overlapping relation.

The'improved corrugated metal sheet 10 is provided-in its body portion with a plurality of (CL 18S-85) V-beam corrugations 12 of substantial depth and at its opposite sides is provided with substantially V-beam corrugations 13, 14 of lesser depth.- Y

The v-heam body corrugations 12 have -subso stantially iiat and relatively short horizontal top walls 15 and relatively wide inclined side walls 16, 17, which latter may and preferably will be at an angle of about 45. l The V-beam side corrugations 13, 14 are proo5 vided with substantially at top horizontal walls 15 and with outer-inclined side walls 20, 21, one or both of which is or are at a greater angle to the horizontal walls 15 than the side waLs 16, 17 and preferably at an angle of about 50.

The side walls 20, 21 of the outside corrugations 13, 14 are narrower or of less width than the'width of the side walls 16, 17 of the body or deeper corrugations 12, and the side walls 20, 21 are preferably made of unequal width, that side wall which is exposed to the weather-when the corrugated sheet is in place on the building, being wider than the side wall which is covered by an adjacent corrugated sheet when'in place on the building.

f In the present instance, the sidewall 20 is the wider one and is illustrated as substantially twice as wide as the narrower side wall 21. The wider side wall 20 in accordance with this invention is inclined from the top 'wall 15 of its V-beam 85 corrugation to make therewith a greater angle than the side walls 16 of the deeper or body corrugations make with their top walls 15, and pref--l erably the side wall 20 is inclined at about 50 to the top wall 15. As a result the complementary angle formed bythe-side wall 20 with a vertical plane normal to the horizontal top wall 15 is sharper or more acute than the complementary angle formed by the side wall 16 or 17 with a vertical plane normal to the top walls 15 of the Y95 deeper corrugations.` The side wall 21 may also be inclined at the sharper angle, as represented in Fig. 5, but inasmuch as the side wall 21 is covered by the overlapping sheet, as represented in Fig; 8, the shorter side wall 21 need not neces- 100 sarily be inclined at the sharper angle, although it may be preferred to so make it, for reasons as will be described, but may be vmade of the same inclination as the side walls 16, `17 of the main or deeper V-beam corrugations.

The side wall 20 is exposed to the weather and it is highly desirable that it should make a weathertight joint with the side wall 16 of the side corrugation of an adjacent V-beam corrusatedmetal sheet.

To this end the side wall 20 which may be designated the weather side wall is made at a sharper angle than the inclined wall 16 of the sheet with which it co-operates and overlaps as shown in Fig. 8, so that when the overlying and underlying V-beam corrugated metal sheets are secured to the building and are drawn toward each other by the bolts, rivets, or other fastening devices, not shown, but which are such as are now commonly used, the sharper side wall 20 and especially the outer edge thereof, will be pressed against the underlying side wall 16 of a different angularity to make a highly eiiicient and superior weathertight joint between the overlapping corrugated V-beam sheets. f

Making the outer side walls of the V-beam corrugations of lesser depth at a greater angle to the top walls 15 of said corrugations and at a sharper or more acute angle to the vertical than the corresponding side walls of'the V-beam corrugations of greater depth, enables the improved V-beam corrugated metal sheets having the superior weather-tight joint above described to be made from flat metal sheets which vary materially in tensile strength, as, for instance, from. 40,000 to 75,000 lbs. tensile strength, inasmuch as the sharper or more acute angle to the vertical oi the outer side walls overcomes the tendency'of these side walls of the V-beam corrugated metal sheet of-lesser strength to spring back and assume a position more nearly approaching the" horizontalas represented in Fiss. 6 and 7, wherein it will be seen that the outer side walls and particularly the weather side walls of the shal-l lower V-beam corrugations are at a less angle to thetop walls 15 than the side walls of the main or deeper corrugations of the V-beam corrugated sheet, which construction of V-beam corrugated sheet is not desirable in 'that a weather-tight joint cannot be made between the weather outer side wall and an underlying V-beam corrugated sheet, when embodied in the roof or side wall of a building. l l

The V-beam sheet having the weather side wall of a V-beam side corrugation of less width than the side walls of the deeper body V-beam corrugations and at a sharper or more acute angle to the vertical than side walls of the body corrugations, may and preferably will be formed by passing the flat metal sheet transversely through a corrugating machine having co-operating rolls -provided with teeth suitably shaped to form the side walls of all the corrugations of the same anrepresented in Fig. 4.

Owing to the variation in the hardness or tensile strength of commercial flat steel sheets available on the market for the production of the improved V-beam corrugated metal sheet, the shorter outside walls of the shallower V-beam corrugations in the hard steelsheets, when released by the corrugating machine, spring back or up toward the horizontal more or less and assume a more nearly flat position, after the manner represented in Figs. 6 and 7.

The corrugated metal sheet represented in Fig. 6 or '7, and produced by feeding the flat metal sheet 'transversely lthrough the corrugating machine whose teeth are of the same angularity, to wit: 45, is then fed longitudinally through a second corrugating machine, having gularity, which may be assumed to be 45, as

rolls provided with teeth of different angularities,

which for the present purposes may be 45 and As represented in Fig. 5, both outside walls of which may be designated the No. 2 machine, are provided between their ends with teeth having a 45 angularity which engage the 45 side walls of the V-beam corrugations of the sheet corrugated by the No. 1 machine, and serve to maintain the deeper body corrugations in their preformed condition.

'I'he corrugated rolls of the No. 2 machine have their end teeth provided with a wall or surface which has a different angularity from the intermediate teeth and in the present case an angularity of 50, and these Walls or surfaces of the end teeth engage the side walls 20, 21 of the sheet corrugated in the No. 1 machine and illustrated in Figs. 6 and 7, and bend saidside walls 90 from an angle on one side of the 45 into an angle on the other side, as, for instance, from a 30 or 40 angle into a 50 angle, as represented in Figs. 5 and 8, and when so bent, said outer side walls of the corrugated sheet remain in the position of greater angularity to the top walls 15, to wit: 50, and provide the V-beam corrugated sheet with side V-beam corrugations which are shall lower or of less depth than the main or body V- beam corrugations, and one or both of which side 100 corrugations has its outer wall at a greater angle to the horizontal top wall 15 of said side corrugation and at a sharper angle ,to a plane normal to said top wall, after the manner represented in Fig. 5.

the shallower corrugations are represented as bent to the greater angle, to wit: 50, but it is not desired to limit -the invention in this respect, as it may be suiicient to bend to the greater angle only the outside wall which is to overlap the adjacent sheet andv be exposed to the weather. In other words, in order to obtain the superior joint between two adjacent sheets of the character described having an overlapping relation, the

weather side wall 20 may be bent to the 50 angle, while the other outside wall, which is covered and protected fromthe weather when in use, need be bent only to the 45 angle, which condition is represented in Fig. 8. 120

By reference'to Fig. 8, it will be seen that-the weather outside wall o20 is at a greater angle to its top wall 15, to wit: 50, than the 45 side wall of an underlying sheet, whereas the covered outside wall 21 of the underlying sheet is bent 125 to a 45 angle.

The improved V-beam corrugated sheet is preferably madewith the weather side wall 20 of greater width than the covered outside wall 21, and it is preferred to make the weather outside '130 wall 20 substantially twice as wide as the covered wall. v

'I'his construction of weather and covered outside walls of the shallower V-beam corrugations enables a nat metal sheetof standard width, to wit: 30" or 36, to be converted into a V-beam corrugated sheet having a maximum number of relatively deep V-beam corrugations provided with substantially flat top and bottom walls in the body portion thereof and shallower V-beam-corruga- 14,() n

tions at the sides of the corrugated sheet, in that the flat sheet may be fed through the No. 1 machine in such manner as to provide the corrugated sheet with the greatest number of deep V-beam corrugations in the body portionthereof while providing a sidewall of a shallower corrugation of sufficient width to enable the superior weather joint to be formed, and asa result a superior corrugated sheet can be produced which is of maximum load-sustaining capacity and has a weather side wall capable of making a tight joint with' a wall of a deep V-beam corrugation in an underlying sheet, and also is capable of maintaining said joint weather-tight by the spring action of the side wall due to the sharper angle, which spring action presses the weather wall against the underlying wall and resists movement of the weatherv wall toward the angularity of the cooperating wall of the underlying sheet. So also, the lsharper angularity of the' weather wall 20 enables the weather-tight joint to be obtained with V-beam corrugated sheets whose weather walls may be forced more or less out of shape in transportation or by a blow in handling the,

sheet on the job, thereby avoiding the necessity of restoring the angularity on the job and careful tting in order to avoid leaks in the roof.

In the present instance, the angularities of the side walls of the deeper V-beam corrugations 12 and'of the outer walls of the shallower side V- beam corrugations 13, 14 have been referred to as 45 and 50 respectively, butit is not desired to limit the invention to these particular angularities, as they may be of other degrees having the same relation.

The process herein described whereby the flat sheet is first provided with V-beam corrugations of greater depth in the body portion and of lesser depth at the sides, and having initially side walls of the same or substantially the same angularity, and then imparting to one or both of the outer walls of the shallower side corrugations a sharper or more acute angularity, enables the improved v-beam corrugated sheet to be produced commercially at a minimum. cost.

The improved V-beam corrugated sheet may be a plain metal sheet, or it may be a protected metal sheet and particularly v a metal sheet protected against corrosion and acid and alkali fumes by asphalt or like bituminous material, and in Fig. 3. such a protected metal sheet is represented, wherein a steel sheet 10 is provided with layers 30 of asphalt, to which is applied layers 3l, 32 of brous material, preferably asbestos felt or the like, and these layers are encased in a protective coating or envelop 33 of bituminous material.

What is claimed is: A corrugated metal sheet having in its body portion substantially V-beam corrugations of sub` stantial depth provided 'with substantially straight ,inclined side walls and with substantially flat top and bottom horizontal walls, and substantially v-beam corrugations of lesser depth at the opposite sides of said sheet having substantially flat top and substantially straight inclined side walls, the outside walls of said outside corrugations being of less width than the width of the corresponding walls of the intermediate deeper corrugations; and one of said outside walls being at a greater angle to its ilat top wall than the correspondingly inclined walls of the intermediate deeper corrugations are to their flat top walls, said angle being suillciently great to enable the outside walls of metal sheets of material tensile strength to resist the spring back of said outside walls toward the horizontal and thereby enable v the corrugated metal sheets to be made from hat metal sheets varying materially in tensile strength' and yet effect a weather-tight Joint with an underlying corrugated sheet.

GEORGE E. BLACK. 

